Functional modules for factory-built homes

ABSTRACT

A factory-built home that is capable of being constructed on a concrete foundation slab is disclosed herein. The home is broken down into a plurality of small functional modules that are supported in a manner that facilitates connection to the concrete foundation slab. For example, a plywood subfloor or a lumber bracing system may be used.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority of U.S. provisional application number 63/070,392, filed Aug. 26, 2020, the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates to factory-built homes and, more particularly, to factory-built homes and factory-built home modules designed for sitting on a concrete foundation slab.

Concrete pad (or slab) foundations are commonly used for site-built homes. In particular, they are more common in states with warm climates where the ground is less likely to freeze and cause cracks in the foundation. However, they cannot accept factory-built homes (or modular homes) because the factory-built homes need to have a way to fasten to the foundation and need space for plumbing connections.

Consequently, these types of homes have an additional material cost and time cost due to needing to be installed on a basement or crawl space foundation. In general, crawl space foundations cost more than concrete slabs and take longer to erect. Further, the home cost is higher because the home must have a floor joist system and a sub floor.

As can be seen, there is a need for a system that reduces construction costs by eliminating the need for a floor joist system in the home and the need for a crawlspace, and therefore also eliminates extra labor that would otherwise be required to construct the home over a crawl space. In addition, building factory-built homes in functional modules, as detailed herein, can also save time and money in transportation and on-site construction.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a factory-built home system comprises: a concrete foundation slab; and a plurality of factory-built functional modules that are each supported by one of a lumber bracing system, prior to assembly, or a subfloor, wherein the plurality of functional modules are assembled on and supported by the concrete foundation slab.

In another aspect of the present invention, a factory-built home comprises: a plurality of factory-built functional modules that are each supported by one of a lumber bracing system, prior to assembly, or a subfloor, wherein the plurality of functional modules are configured to be assembled on and supported by a concrete foundation slab.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of the present disclosure and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

FIG. 1 is a wide-angle perspective view showing an embodiment of the present invention, with a roof removed for clarity;

FIG. 2 is a wide-angle perspective view of the embodiment of the present invention, similar to FIG. 1, showing a functional module exploded from the overall structure;

FIG. 3 is a perspective detail view of a functional module of the embodiment of the present invention;

FIG. 4 is a top perspective view of a complete home of the embodiment of the present invention sitting on a concrete foundation slab;

FIG. 5 is a perspective detail of a functional module of the embodiment of the present invention, similar to FIG. 3, with a subfloor removed and a bracing system utilized for support instead;

FIG. 6 is a perspective view of the concrete foundation slab of the embodiment of the present invention; and

FIG. 7 is a wide-angle perspective view, similar to FIG. 2, of the overall structure installed on the concrete foundation slab, with one functional module exploded from the overall structure.

DETAILED DESCRIPTION OF THE INVENTION

The subject disclosure is described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure such that one skilled in the art will be enabled to make and use the present invention. It may be evident, however, that the present disclosure may be practiced without some of these specific details.

Broadly, one embodiment of the present invention is a factory-built home that includes a plurality of functional modules and is capable of being constructed on a concrete foundation slab. As mentioned above, the present disclosure is directed to concrete foundation slabs for factory-built homes and factory-built functional home modules. Using the teachings of the present invention, factory-built homes are now capable of being constructed on a concrete pad foundation (rather than over, for example, a crawl space), thus reducing the cost and labor required to construct the foundation and build and install the home.

In addition, building a factory-built home in functional modules, as described in greater detail below, can also save time and money in terms of transportation and construction. The term “functional modules”, as herein used, includes but is not limited to: bathrooms, bedrooms, kitchens, living rooms, etc. These functional modules include a plurality of walls and a number of functional elements installed therewithin. In addition, functional modules of the present invention eliminate the need for factory-built homes to have rim joists and duplicate walls along the marriage line (the area of the functional module that has been joined to another functional module) of the home.

The present invention advantageously requires much smaller factories for constructing functional modules in accordance with the present invention, as opposed to entire sections of a home. A typical factory today is approximately 200,000 square ft. A factory for making functional modules described herein can be as small as 1000 sq. ft. In addition, the smaller factories can be located closer to customers with reduced delivery costs and faster turnaround time. Conventional factory home big sections are transported by tractor trailer trucks. These functional modules can be transported by much smaller pick-up trucks. Also, since the modules are smaller, they can be set by much smaller equipment and fewer workers.

Making reference now to FIGS. 1-7, a factory-built home 10 (excluding the roof) includes a first building unit 12 a (upper structure in FIG. 1) and a second building unit 12 b (lower structure in FIG. 1), with a split line 12 c generally dividing the two units 12 a, 12 b. A traditional factory-built home is provided in two large sections, like units 12 a, 12 b denote, which differs from the functional modules referenced above, and described in greater detail below.

Advantageously, embodiments of the present invention provide the home 10 in a set of functional modules 18 that couple together (e.g., see FIG. 2 to FIG. 1), with a plurality of functional modules 18 forming the first building unit 12 a and the second building unit 12 a referenced above. Each functional module 18 may define a room 14 (or at least a portion of one) or another functional space in the home 10 (such as a utility closet). Depending upon location within the overall home 10, each functional module 18 may include various combinations of exterior walls 16 a and interior walls 16 b. These functional modules 18 reduce construction and transportation costs. As mentioned above, modules 18 include functional sections of a home, such as but not limited to: kitchens, bathrooms, living rooms, and utility rooms, which are examples of functional modules 18 that can be built separately in the factory and then assembled into one house on site on a concrete slab 24 (also referred to as a concrete pad).

FIG. 4 illustrates an assembled and installed factory-built home 20 including a roof 22. The roof 22 may be installed on site, and when installed on an embodiment of the present invention, can be any material or pitch. Conversely, manufactured homes cannot use metal roofs over 3/12 pitch.

FIG. 6 shows a simplified version of a concrete foundation slab 24 with a plurality of plumbing pipes being provided substantially flush with a top surface of the slab 24. As mentioned above, the smaller functional modules 18 of the present disclosure cost less to transport and erect on site (on top of the slab 24), in part, since they are considerable lighter than the typical two section modular home modules. In addition, functional modules 18 can be made in smaller, less expensive factories and shipped less expensively due to their smaller size and weight. Advantageously, the factory-built functional modules 18 manufactured in accordance with the present invention may be fastened to the concrete slab 24 (e.g., see FIG. 7) using traditional bottom plate and straps connections.

Returning to discussion regarding the functional modules 18, and as shown in FIG. 3, the functional modules 18 may each be mounted on a subfloor 26. This subfloor method eliminates the typical floor joist and insulation normally found in a factory-built home and allows for normal construction of the factory-built home 10. In accordance with the present invention, factory-built homes 10 are constructed in the factory on a subfloor 26 and a floor joists system supported by a rim joist. The functional modules 18 may also be constructed in the factory directly on a carrier transport that supports the subfloor 26. The factory subfloor 26 may be formed from plywood or other materials suitable for the application (such as pre-cast concrete). As shown in FIG. 7, plumbing holes 28 may be precut in the subfloor 26 to mate with plumbing pipes 32 in the concrete foundation slab 24 upon which the factory-built home 10 is installed/rests on. After the home 10 is set (as shown in FIG. 7), plumbing connections can then easily be made to connect the plumbing in the home 10.

Compared to a typical frame of a typical factory-built home, the frame for the factory-built home 10 does not change from a fundamental standpoint. Structurally, the frame of the present invention is similar to that of a typical frame, but it is, importantly, provided in smaller modules 18 (which is, accordingly, lighter and easier to work with than the prior art), which reduces costs to transport and set up. After transport, the home 10 is moved off the home transport carrier and onto the concrete slab 24 at the construction site. The concrete slab 24 is made to local codes and the plumbing interface pipes 32 (as well as drains) are located either flush or recessed with the slab 24.

Alternatively, rather than including a subfloor 26, in certain embodiments, the factory-built home 10 may be built directly on the carrier and exclude a subfloor 26. In lieu of the previously described subfloor 26, and as shown in FIG. 5, a bracing system 30 may be used to support the interior walls 16 b of the home 10 during transportation and construction on a concrete slab. By way of example, 2 inches by 4 inches dimensional lumber may be used to brace the walls 16 b every 8 feet (or as needed), with the lumber supporting the wall 16 b and engaging the carrier directly (since there is no subfloor). This bracing system 30 may stay in place until the home 10 or functional modules 18 are in their final place on the concrete foundation slab 24.

To make embodiments of the present invention, ¾ inch or thicker moisture treated plywood may be utilized as the subfloor 26. The concrete slab 24 may be poured like a traditional slab on grade pad (rather than needing to use a more expensive crawl space foundation), with the plumbing 32 installed and cut to be flush with the slab 24. The home 10 or functional modules 18 are then set on top of the slab 24 and the home 10 may then be finished (e.g., plumbing connections made, roof installed, etc.).

Further methods of making and installing a factory-built home system may include the following. A concrete foundation slab 24 is provided. Further, factory-built functional modules 18 are provided that are each supported by one of a lumber bracing system, prior to assembly, or a subfloor 26. In use, then the functional modules 18 are assembled on and supported by the concrete foundation slab 24. Even further, the subfloor may be provided with several holes 28 to make plumbing connections. Even further, plumbing pipes 32 may be embedded within the concrete foundation slab 24 and terminate flush (or slightly recessed) with a top surface of the concrete foundation slab to connect to plumbing pipes in the functional modules 18.

Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein.

While apparatuses and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the apparatuses and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

Moreover, the use of directional terms such as above, below, upper, lower, upward, downward, left, right, and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward or upper direction being toward the top of the corresponding figure and the downward or lower direction being toward the bottom of the corresponding figure.

As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C. 

What is claimed is:
 1. A factory-built home system comprising: a concrete foundation slab; and a plurality of factory-built functional modules that are each supported by one of a lumber bracing system, prior to assembly, or a subfloor, wherein the plurality of functional modules are assembled on and supported by the concrete foundation slab.
 2. The factory-built home system of claim 1, wherein each factory-built functional module defines a functional section, with each functional section being selected from the group consisting of: a kitchen, a bathroom, a living room, a dining room, an office, and a utility room.
 3. The factory-built home system of claim 1, further comprising plumbing pipes embedded within the concrete foundation slab and terminating substantially flush with a top surface of the concrete foundation slab.
 4. The factory-built home system of claim 3, wherein each factory-built functional module comprises the subfloor, and the subfloor defines holes for making connections with plumbing pipes embedded in the concrete foundation slab.
 5. The factory-built home system of claim 1, wherein each factory-built functional module comprises the subfloor, and the subfloor comprises plywood.
 6. A factory-built home comprising: a plurality of factory-built functional modules that are each supported by one of a lumber bracing system, prior to assembly, or a subfloor, wherein the plurality of functional modules are configured to be assembled on and supported by a concrete foundation slab.
 7. The factory-built home of claim 6, wherein each factory-built functional module defines a functional section, with each functional section being selected from the group consisting of: a kitchen, a bathroom, a living room, a dining room, an office, and a utility room.
 8. The factory-built home of claim 6, wherein each factory-built functional module comprises the subfloor, and the subfloor comprises plywood.
 9. The factory-built home of claim 6, wherein each factory-built functional module comprises the subfloor, and the subfloor comprises holes for making connections with plumbing pipes embedded in the concrete foundation slab.
 10. The factory-built home of claim 6, wherein each factory-built functional module comprises the lumber bracing system, and the lumber bracing system comprises a plurality of lumber that supports walls of each factory-built functional module. 